Article of footwear having protruding members

ABSTRACT

An article of footwear includes an upper, a sole structure, and a cleat assembly connected to the sole structure. The cleat assembly includes a plurality of protruding members that extend from a base. Each protruding member includes a side wall that defines a first exterior angle and a second exterior angle relative to the base when viewed from one of a medial side or a lateral side of the article of footwear. The first exterior angle is greater than the second exterior angle.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser. No. 63/137,899, filed on Jan. 15, 2021, the contents of which is incorporated by reference herein in its entirety and is to be considered part of this application.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENCE LISTING

Not applicable

BACKGROUND 1. Field of the Invention

The present disclosure relates generally to an article of footwear including a cleat assembly having protruding members that extend from a base portion.

2. Description of the Background

Many conventional shoes or articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, which is created by interior surfaces of the upper and sole, to receive a foot of a wearer before securing the shoe to the foot. The sole is attached to a lower surface of the upper and is positioned between the upper and the ground. As a result, the sole typically provides stability and cushioning to the wearer when the shoe is being worn and/or is in use. In some instances, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole may provide traction to a bottom surface of the sole, and the midsole may be attached to an inner surface of the outsole and may provide cushioning and/or added stability to the sole. For example, a sole may include a particular foam material that may increase stability at one or more desired locations along the sole, or a foam material that may reduce stress or impact energy on the foot and/or leg during running, walking, or another activity.

The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases a foot. In most cases, an upper extends over instep and toe regions of the foot, and across medial and lateral sides thereof. Many articles of footwear may also include a tongue that extends across the instep region to bridge a gap between edges of the upper that define an opening into the cavity. The tongue may also be provided below a lacing system, which may be provided to allow for adjustment of shoe tightness, and may be manipulable by a user to permit entry and/or exit of a foot from the internal space or cavity. In addition, the lacing system may allow a wearer to adjust certain dimensions of the upper and/or the sole, thereby allowing the upper to accommodate a wide variety of foot types having varying sizes and shapes.

The upper of many shoes may comprise a wide variety of materials, which may be utilized to form the upper and chosen for use based on one or more intended uses of the shoe. The upper may also include portions comprising varying materials specific to a particular area of the upper. For example, added stability may be desirable at a front of the upper or adjacent a heel region so as to provide a higher degree of resistance or rigidity. In contrast, other portions of a shoe may include a soft woven textile to provide an area with stretch-resistance, flexibility, air-permeability, or moisture-wicking properties.

However, in many cases, articles of footwear having uppers with an increased comfort and better fit are desired, along with soles having improved structural characteristics such as a cleat assembly secured to the sole structure to improve ground traction.

SUMMARY

An article of footwear, as described herein, may have various configurations. The article of footwear may have an upper and a sole structure connected to the upper.

Some embodiments of the present disclosure provide an article of footwear that includes an upper, a sole structure connected to the upper, and a cleat assembly connected to the sole structure. The cleat assembly can include a first protruding member that extends from a first base. The first protruding member can define a first midfoot-facing portion and a forefoot facing portion. A second protruding member can extend from a second base and can define a second midfoot-facing portion and a heel-facing portion. A first acute angle can be defined by the first base and the first midfoot-facing portion. A first obtuse angle can be defined by the first base and the forefoot facing portion. A second acute angle can be defined by the second base and the second midfoot-facing portion. A second obtuse angle can be defined by the second base and the heel-facing portion.

In some embodiments, an article of footwear can include a first obtuse angle and a second obtuse angle that are both between 95 degrees and 145 degrees, inclusive.

In some embodiments, an article of footwear can include a first acute angle and a second acute angle that are both between 35 and 85 degrees, inclusive.

In some embodiments, an article of footwear can include a first base formed from a forefoot portion of a cleat assembly. The forefoot portion of the cleat assembly can be at least partially disposed in a forefoot region of the article of footwear. A second base can be formed from a heel portion of the cleat assembly. The heel portion of the cleat assembly can be at least partially disposed in a heel region of the article of footwear.

In some embodiments, an article of footwear can include a first protruding member that is part of a first plurality of protruding members. A second protruding member can be part of a second plurality of protruding members.

In some embodiments, an article of footwear can include at least one protruding member of a first or second plurality of protruding members that includes a ground engaging surface that is parallel to a portion of a base.

In some embodiments, an article of footwear can include a first plurality of protruding members and a second plurality of protruding members. Each of the protruding members of the first and second pluralities of protruding members can be angled toward a midfoot region of the article of footwear.

In some embodiments, an article of footwear can include a first plurality of protruding members that are integrally formed. A second plurality of protruding members can be additionally or alternatively integrally formed.

In some embodiments, an article of footwear can include one or more protruding members that include a removable stud tip.

In some embodiments, an article of footwear can include one or more protruding members that are injection molded from a scratch-resistant polymer, such as, for example, polybenzimidazole, polyparaphenylene, polyetheretherketone, polyimide, acrylonitrile butadiene styrene, coated polypropylene, or other additives added to a polymer, such as polypropylene.

In some embodiments, an article of footwear can include a first protruding member that includes a tapered geometry so that a wider portion of the first protruding member is disposed proximate to a first base and a second protruding member can include a tapered geometry so that a wider portion of the second protruding member is disposed proximate to a second base.

Some embodiments of the present disclosure provide an article of footwear that includes an upper, a sole structure connected to the upper and defining a forefoot region, a midfoot region, and a heel region, and a cleat assembly secured to the sole structure. The cleat assembly can include a forefoot portion secured to the sole structure at the forefoot region. The forefoot portion can include a first plurality of protruding members that extend from a first base. The first plurality of protruding members can be angled toward the midfoot region. A heel portion of the cleat assembly can be secured to the sole structure at the heel region. The heel portion can include a second plurality of protruding member extending from a second base. The second plurality of protruding members can be angled toward the midfoot region.

In some embodiments, an article of footwear can include a plurality of protruding members. Each protruding member of the plurality of protruding members can include a ground engaging surface. Each ground engaging surface can define a surface area that may vary between protruding members. The surface are of the protruding members closest to a midfoot region of the article of footwear may be greater than the surface area of the protruding members closest to a forefoot or a heel region of the article of footwear.

In some embodiments, an article of footwear can include a plurality of protruding members that include a removable stud tip.

In some embodiments, an article of footwear can include a first base portion integrally formed with a first protruding member and a second base portion integrally formed with a second protruding member. Each of the base portions may be separate and distinct.

In some embodiments, an article of footwear can include a protruding member in a forefoot region that can define a midfoot-facing side wall and a forefoot-facing side wall (e.g., when viewed from a side view of the article of footwear). The midfoot-facing side wall can form an acute angle with a base and the forefoot-facing side wall can form an obtuse angle with the base. In general, the protruding member can extend downward from the base.

In some embodiments, an article of footwear can include a protruding member having a midfoot-facing side wall and a forefoot-facing side wall that are integrally formed with each other.

In some embodiments, an article of footwear can include a protruding member in a heel region that can define a midfoot-facing side wall and a heel-facing side wall (e.g., when viewed from a side view of the article of footwear). The midfoot-facing side wall can form an acute angle with a base and the heel-facing side wall can form an obtuse angle with the base. In general, the protruding member can extend downward from the base.

Some embodiments of the present disclosure provide a method of forming a cleat assembly for an article of footwear. The method can include injecting a first material into a mold cavity to form a cleat assembly. The mold cavity can include a plurality of stud recesses that each define a respective stud recess base disposed along an incline that defines an acute exterior angle relative to horizontal plane. The horizontal plane may be disposed outside of the mold cavity. The method can also include removing the cleat assembly from the mold cavity at an angle that is substantially perpendicular to the horizontal plane.

In some embodiments, a method of forming a cleat assembly for an article of footwear can include securing a cleat assembly to a sole structure of the article of footwear.

Some embodiments of the present disclosure provide an article of footwear including an upper, a sole structure, and a cleat assembly connected to the sole structure. The cleat assembly includes a plurality of protruding members that extend from a base. Each protruding member includes a side wall that defines a first exterior angle and a second exterior angle relative to the base when viewed from one of a medial side or a lateral side of the article of footwear. The first exterior angle is greater than the second exterior angle.

In some embodiments, the present disclosure provides an article of footwear including an upper, a sole structure connected to the upper, and a cleat assembly connected to the sole structure. The cleat assembly can include a first protruding member that extends from a first base. The first protruding member can define a first midfoot-facing portion and a forefoot facing portion. A second protruding member can extend from a second base and define a second midfoot-facing portion and a heel-facing portion. A first acute angle can be defined by the first base and the first midfoot-facing portion. A first obtuse angle can be defined by the first base and the forefoot facing portion. A second acute angle can be defined by the second base and the second midfoot-facing portion. A second obtuse angle can be defined by the second base and the heel-facing portion.

Other aspects of the article of footwear, including features and advantages thereof, will become apparent to one of ordinary skill in the art upon examination of the figures and detailed description herein. Therefore, all such aspects of the article of footwear are intended to be included in the detailed description and this summary.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top lateral isometric view of an article of footwear configured as a left shoe that includes a cleat assembly according to an embodiment of the disclosure;

FIG. 2 is a lateral side view of the article of footwear of FIG. 1;

FIG. 3 is a top view of the article of footwear of FIG. 1;

FIG. 4 is a schematic illustration of layers of an upper of the article of footwear of FIG. 1;

FIG. 5 is a schematic illustration of a portion of a tongue of the article of footwear of FIG. 1;

FIG. 6 is a schematic illustration of a mold for a portion of the cleat assembly of FIG. 1;

FIG. 7 is a schematic illustration of a mold opening of the mold of FIG. 6;

FIG. 8 is a side view of a protruding member of the cleat assembly of FIG. 1;

FIG. 9 is a schematic illustration of a profile of a protruding member according to an embodiment of the disclosure;

FIG. 10 is another schematic illustration of a profile of a protruding member according to an embodiment of the disclosure;

FIG. 11 is a medial side view of a sole structure of an article of footwear that includes a cleat assembly according to an embodiment of the disclosure;

FIG. 12 is a bottom view of the sole structure of FIG. 11;

FIG. 13 is a lateral side view of the sole structure of FIG. 11;

FIG. 14 is a cross-sectional side view of the sole structure of FIG. 12 taken along line A-A thereof;

FIG. 15 is a top view of the sole structure of FIG. 11;

FIG. 16 is a cross-sectional view of the sole structure of FIG. 12 taken along line B-B thereof;

FIG. 17 is a cross-sectional view of the sole structure of FIG. 12 taken along the line C-C thereof;

FIG. 18 is a cross-sectional view of the sole structure of FIG. 12 taken along the line D-D thereof;

FIG. 19 is a cross sectional view of the sole structure of FIG. 12 taken along the line E-E thereof;

FIG. 20 is a cross-sectional view of the sole structure of FIG. 12 taken along the line F-F thereof;

FIG. 21 is a cross-sectional view of the sole structure of FIG. 12 taken along the line G-G thereof; and

FIG. 22 is a schematic illustration of a mold for a cleat assembly according to an embodiment of the disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe that may include an upper and a sole structure. Although embodiments of a shoe or sole structure are disclosed with reference to a sports shoe, such as a running shoe, tennis shoe, basketball shoe, etc., concepts associated with embodiments of the shoe or the sole structure may be applied to a wide range of footwear and footwear styles, including cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats, for example. Concepts of the shoe or the sole structure may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, particular concepts described herein may also be applied and incorporated in other types of apparel or other athletic equipment, including helmets, padding or protective pads, shin guards, and gloves. Even further, particular concepts described herein may be incorporated in cushions, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, concepts described herein may be utilized in a variety of products.

The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.

The terms “weight percent,” “wt-%,” “percent by weight,” “% by weight,” and variations thereof, as used herein, refer to the concentration of a substance or component as the weight of that substance or component divided by the total weight, for example, of the composition or of a particular component of the composition, and multiplied by 100. It is understood that, as used herein, “percent,” “%,” and the like may be synonymous with “weight percent” and “wt-%.”

The present disclosure is directed to an article of footwear and/or specific components of the article of footwear, such as an upper and/or a sole or sole structure. The upper may comprise a knitted component, a woven textile, and/or a non-woven textile. The knitted component may be made by knitting of yarn, the woven textile by weaving of yarn, and the non-woven textile by manufacture of a unitary non-woven web. Knitted textiles include textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, and/or other suitable knitting operations. The knit textile may have a plain knit structure, a mesh knit structure, and/or a rib knit structure, for example. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, and/or double cloth weaves, for example. Non-woven textiles include textiles made by air-laid and/or spun-laid methods, for example. The upper may comprise a variety of materials, such as a first yarn, a second yarn, and/or a third yarn, which may have varying properties or varying visual characteristics.

FIGS. 1-3 depict an exemplary embodiment of an article of footwear 100 including an upper 102 and a sole structure 104. The upper 102 is attached to the sole structure 104 and together define an interior cavity 106 into which a foot may be inserted. For reference, the article of footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 generally corresponds with portions of the article of footwear 100 that encase portions of the foot that include the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 110 is proximate and adjoining the forefoot region 108, and generally corresponds with portions of the article of footwear 100 that encase the arch of a foot, along with the bridge of a foot. The heel region 112 is proximate and adjoining the midfoot region 110 and generally corresponds with portions of the article of footwear 100 that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.

Many conventional footwear uppers are formed from multiple elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined through bonding or stitching at a seam. In particular, with reference to FIGS. 4 and 5, the upper 102 may be formed from a first layer 114 and a second layer 116. The first layer 114 can include a plurality of recesses 118 configured as holes that promote breathability through the upper 102. The second layer 116 can be at least partially transparent and pressed to the first layer 114. Illustrated in FIG. 4, the second layer 116 is configured as a skin having a pattern such as dots or pixels. As shown in FIG. 5, a tongue portion 120 of the article of footwear 100 similarly includes the first layer 114 having the plurality of recesses 118 to further increase breathability in the upper 102.

The article of footwear 100 also includes a medial side 122 and a lateral side 124 illustrated in FIG. 3. In particular, the lateral side 124 corresponds to an outside portion of the article of footwear 100 and the medial side 122 corresponds to an inside portion of the article of footwear 100. As such, left and right articles of footwear have opposing lateral and medial sides, such that the medial sides 122 are closest to one another when a user is wearing the articles of footwear 100, while the lateral sides 124 are defined as the sides that are farthest from one another while being worn. The medial side 122 and the lateral side 124 adjoin one another at opposing, distal ends of the article of footwear 100.

Unless otherwise specified, the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 122, and the lateral side 124 are intended to define boundaries or areas of the article of footwear 100. To that end, the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 122, and the lateral side 124 generally characterize sections of the article of footwear 100. Further, both the upper 102 and the sole structure 104 may be characterized as having portions within the forefoot region 108, the midfoot region 110, the heel region 112, and on the medial side 122 and the lateral side 124. Therefore, the upper 102 and the sole structure 104, and/or individual portions of the upper 102 and the sole structure 104, may include portions thereof that are disposed within the forefoot region 108, the midfoot region 110, the heel region 112, and on the medial side 122 and the lateral side 124.

The sole structure 104 is connected or secured to the upper 102 and extends between a foot of a user and the ground when the article of footwear 100 is worn by the user. The sole structure 104 may include one or more components, which may include an outsole, a midsole, a heel, a vamp, and/or an insole. For example, in some embodiments, a sole structure may include an outsole that provides structural integrity to the sole structure, along with providing traction for a user, a midsole that provides a cushioning system, and an insole that provides support for an arch of a user.

With reference again to FIGS. 1 and 2, the sole structure 104 includes a cleat assembly 130. The cleat assembly 130 includes a forefoot portion 132 and a heel portion 134. The forefoot portion 132 includes a plurality of protruding members 136 and a base portion 138. The plurality of protruding members 136 extend from the base portion 138 and can define at least two distinct angles between a side wall 140 of each protruding member 136 and the base portion 138 when viewed in a side view.

In the illustrated embodiment, the side wall 140 is configured as an outer surface of a cylinder. As shown, for example in FIGS. 1 and 2, the cylinder can be configured as a tapered cylinder (e.g., a frustum) with a wider portion disposed proximate to the base portion 138. In other embodiments, the protruding member 136 may be faceted and a side wall may be only a single facet of the faceted outer surface of the protruding member 136. As such, a first side wall defined by a first facet can define a first angle between the first facet and the base portion 138 and a second side wall defined by a second facet of the same protruding member can define a second angle between the second facet and the base portion 138. The first angle can be different from the second angle.

The distinct and different angles of the protruding members 136 formed by the side walls 140 and the base portion 138 when viewed in a side view can vary between individual protruding members 136 of the plurality of protruding members. Additional details of such distinct angles will be described below with reference to FIGS. 8-10. Similarly, the heel portion 134 includes a plurality of protruding members 144 that extend from a base portion 146. Like the forefoot portion 132, one or more of the protruding members 144 of the heel portion 134 can define at least two distinct angles between a side wall 148 of each protruding member 144 and the base portion 146.

Each of the plurality of protruding members 136, 144 include a respective ground engaging surface 150 that is generally bounded by the respective side wall 140, 148. In an embodiment where the plurality of protruding members 136, 144 include faceted surfaces, a ground engaging surface can be generally bound by the faceted surfaces. Each protruding member 136 of the forefoot portion 132 can include varying sizes (e.g., surface area) of ground engaging surfaces 150. For example, the ground engaging surfaces 150 of the protruding members 136 closer to the midfoot region 110 of the article of footwear 100 may be greater than the ground engaging surfaces 150 of the protruding members 136 closer to the forefoot region 108. Likewise, the surface area of the grounding engaging surfaces 150 may vary with respect to the position of the protruding members 136 relative to the medial side 122 and the lateral side 124 of the article of footwear 100. In the illustrated embodiment, the ground engaging surfaces 150 are generally planar. However, in other embodiments, protruding members can include ground engaging surfaces having generally convex or concave geometries.

In general, each of the forefoot portion 132 and the heel portion 134 of the cleat assembly 130 can be formed via injection molding. For example, in some embodiments, an injection mold, such as mold 160 illustrated in FIG. 6, can be used to form the forefoot portion 132 of the cleat assembly 130. The mold 160 is configured as a two-piece rigid mold and includes a cavity 162 having a plurality of recesses that correspond to the geometry of the plurality of protruding members 136. The cavity 162 is formed in an angled portion 164 of the mold 160. The angled portion 164 relative to the cavity 162 promotes successful removal of the forefoot portion 132 of the cleat assembly 130 from the mold 160 and eliminates undercut features of the cleat assembly 130.

In some embodiments, during a manufacturing process, preformed stud tips may be added to the cavity 162 and inserted into the plurality of recesses before the injection molding process. The preformed stud tips can be formed from a different material than the injection material to form the cleat assembly 130. For example, the stud tips may be formed from a relatively abrasion or scratch-resistant material compared to the injection material, which may be a polymer injection material. Additionally, in some embodiments the cleat assembly 130 can include removable stud tips. For example, the stud tips can be secured to the forefoot portion 132 and the heel portion 134 via a threaded fastener.

Illustrated in FIG. 7, the portion of the mold 160 that corresponds to the ground engaging surfaces 150 of the protruding members 136 is generally parallel (e.g., angled acutely or substantially parallel) to the angled portion 164 of the mold 160. Such geometry further reduces undercut features formed in the cleat assembly 130. Corresponding molds and mold features illustrated in FIGS. 6 and 7 can be used to produce the heel portion 134 of the cleat assembly 130.

FIG. 8 illustrates a single protruding member 136A of the forefoot portion 132 of the cleat assembly 130. It should be understood that the protruding member 136A is illustrated by way of example and can correspond to one or more of any of the protruding members 136, 144. In particular, the reference lines illustrated in FIG. 8 can generally correspond to any of the protruding members 136, 144 regardless of relative angle with respect to an axis, such as axis 170, that extends along the base portion 138 adjacent to one of the plurality of protruding members 136 in an elevational side view. In this regard, the reference lines (e.g., lines 172, 174) can correspond to a variety of side walls of the protruding members 134, 144, and can intersect a base reference line (e.g., line 170) at a variety of angles.

In the illustrated embodiment, the protruding member 136A defines an axis 170 that extends along the base portion 138. A first portion of the side wall 140 is disposed at least partially along a first line 172 and a second portion of the side wall 140 is disposed along a second line 174. The first line 172 intersects the axis 170 at a first exterior angle 176 and the second line 174 intersects the axis 170 at a second exterior angle 178. The first exterior angle 176 is obtuse (i.e., greater than 90 degrees) and faces the forefoot region 108 of the article of footwear 100 (see, for example, FIGS. 1 and 2). The second exterior angle 178 is acute (i.e., less than 90 degrees) and faces the midfoot region 110 of the article of footwear 100. In general, the angles illustrated in FIG. 8 can facilitate removal from an injection mold while providing sufficient ground contacting area and strength during use.

Each protruding member 144 of the heel portion 134 can correspondingly define a first exterior angle formed by the portion of the side wall 148 that faces the heel region 112 of the article of footwear 100 and the base portion 146. Additionally, each protruding member 144 of the heel portion 134 can define a corresponding second exterior angle formed by the portion of the side wall 148 that faces the midfoot region 110 of the article of footwear 100 and the base portion 146. Like the protruding member 136A, the first exterior angle of the protruding member 144 of the heel portion 134 is obtuse and the second exterior angle of the protruding member 144 of the heel portion 134 is acute.

In general, the first exterior angle 176 can be between approximately 95 degrees and 145 degrees. Additionally, the second exterior angle 178 can be between approximately 35 degrees and 85 degrees. Therefore, each exterior angle of the protruding members 136, 144 that faces an outer end of the article of footwear 100 (i.e., the forefoot region 108 or the heel region 112) can be between approximately 95 and 145 degrees. Additionally or alternatively, each exterior angle of the protruding members 136, 144 that faces the midfoot region 110 of the article of footwear 100 can be between approximately 45 degrees and 85 degrees.

FIGS. 9 and 10 illustrate additional geometries of protruding members according to some embodiments of the disclosure. For example, FIG. 9 illustrates a protruding member 200 that extends from a base surface 202 and includes a side wall 204 and a ground engaging surface 206. One side of the side wall 204 that faces an end of an article of footwear (i.e., a forefoot region or a heel region) forms a first angle 208 with the base surface 202. A second side of the side wall 204 that faces a midfoot region of the article of footwear forms a second angle 210 with the base surface 202. In the illustrated example, the first angle 208 is approximately 110 degrees and the second angle 210 is approximately 70 degrees.

FIG. 10 illustrates a protruding member 220 that extends from a base surface 222 and includes a side wall 224 and a ground engaging surface 226. One side wall of 224 that faces an end of an article of footwear forms a first angle 228 with the base surface. A second side of the side wall 224 that faces a midfoot region of the article of footwear forms a second angle 230 with the base surface 222. In the illustrated example, the first angle 228 is approximately 110 degrees and the second angle 230 is approximately 80 degrees.

The ground engaging surfaces 206, 226 illustrated in FIGS. 9 and 10, respectively, are generally parallel to the corresponding base surface 202, 222. However, in other embodiments, one or more ground engaging surfaces of a cleat assembly can be skewed relative to a base portion. Each of the protruding members 200, 220 provide an example geometry that may be used by one or more of the plurality of protruding members 136, 144 of the cleat assembly 130.

FIGS. 11-21 depict an exemplary embodiment of a sole structure 240 according to one embodiment of the invention. Similar to the sole structure 104, the sole structure 240 is configured to be attached to an upper and together define an interior cavity into which a foot may be inserted. For reference the sole structure 240 defines a forefoot region 248, a midfoot region 250, and a heel region 252. The forefoot region 248 generally corresponds with portions of an article of footwear, such as the article of footwear 100, for example, that encase portions of the foot that include the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 250 is proximate and adjoining the forefoot region 248, and generally corresponds with portions of the article of footwear that encase the arch of a foot, along with the bridge of a foot. The heel region 252 is proximate and adjoining the midfoot region 250 and generally corresponds with portions of the article of footwear that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.

The sole structure 240 also includes a medial side 256 illustrated in FIG. 11 and a lateral side 258 illustrated in FIG. 13. In particular, the lateral side 258 corresponds to an outside portion of the article of footwear and the medial side 256 corresponds to an inside portion of the article of footwear. As such, left and right articles of footwear have opposing lateral and medial sides, such that the medial sides are closest to one another when a user is wearing the articles of footwear, while the lateral sides are defined as the sides that are farthest from one another while being worn. The medial side 256 and the lateral side 258 adjoin one another at opposing, distal ends of the article of footwear.

Similar to the sole structure 104, the sole structure 240 includes a cleat assembly 260. The cleat assembly 260 includes a forefoot portion 262 and a heel portion 264. The forefoot portion 262 includes a plurality of protruding members 266 and a base portion 268. The plurality of protruding members 266 extend from the base portion 268 and can define a first exterior angle 270 a second exterior angle 272 with respect to the base portion 268. Similarly, the heel portion 264 includes a plurality of protruding members 274 that extend from a base portion 276. Like the forefoot portion 262, one or more of the protruding members 274 of the heel portion 264 can define a first exterior angle 278 and a second exterior angle 280.

In some embodiments, forefoot portion 262 can include a unitary body such that the plurality of protruding members 266 and the base portion 268 are integrally formed. Similarly, the heel portion 264 can include a unitary body such that at least one of the plurality of protruding members 274 are integrally formed with the base portion 274. In other embodiments, each of the forefoot portion 262 and the heel portion 264 can include one or more base portions 268, 274, respectively.

Illustrated in FIGS. 11 and 13, each of the first exterior angles 270, 278 face an outer end of the sole structure 240 (i.e., the forefoot region 248 or the heel region 252) and each of the second exterior angles 272, 280 face a center of the sole structure 240 (i.e., the midfoot region 250). The first exterior angles 270, 278 are between approximately 95 degrees and 145 degrees. The second exterior angles 280 are between approximately 35 degrees and 85 degrees.

Referring now to FIGS. 16-21, the plurality of protruding members 266, 274 extend generally perpendicularly downward from the respective base portion 268, 276 when viewed from a toe or heel end of the article of footwear. Additionally, each protruding member 266, 274 can include a stud member 282 that extends beyond the respective protruding member 266, 274 that forms a ground engaging surface 284. As illustrated in FIGS. 16 and 21, some ground engaging members 284 of the cleat assembly 260 can be disposed on substantially the same plane. Additionally, as illustrated in FIG. 17, some ground engaging surfaces 284 of the cleat assembly 260 can be disposed on distinct planes.

FIG. 22 illustrates a mold 300 for a sole structure, such as the sole structure 104, for example. Similar to the sole structure 104, the mold 300 can include forefoot portion 302 and a heel portion 304. In general, the mold 300 defines a negative space including a plurality of stud recesses 308 (e.g., stud recesses 308A-D). Each of the plurality of stud recesses 308 define a respective base 310 (e.g., bases 310A-D). Each of the plurality of bases 310 in the forefoot portion 302 are generally disposed along an incline 312. For example, a first stud recess 308A of the plurality of stud recesses 308 defines a first base 308A disposed along a first incline, a second stud recess 308B defines a second base 310B disposed along a second incline, and a third stud recess 308C defines a third base 308C disposed along a third incline.

In the illustrated embodiment, each of the first, second, and third inclines are sloped in the same direction as the general incline 312. Further, in the illustrated embodiment, the first sloped portion of the first base 310A is slightly skewed relative to the general incline 312 (e.g., less than 30 degrees) and the third sloped portion of the third base 310C is slightly skewed relative to the general incline 312 (e.g., less than 10 degrees). Further, as illustrated, the general incline 312, and therefore each of the first, second, and third inclines, form an acute angle with respect to a horizontal plane 318. A fourth stud recess 308D formed in the heel portion 304 defines a fourth base 308D disposed along an incline having an opposing slope to the general incline 312 of the forefoot portion 302.

The incline of each base 310 of the plurality of stud recesses 308 allows a sole structure to be removed from the mold 300 generally perpendicular to the horizontal plane 318. When a material is injected into the mold 300 to form a sole structure, the general incline of each of the forefoot portion 302 and the heel portion 304, (e.g., the incline 312) allows studs formed in the corresponding plurality of stud recesses 308 to define a straight center line 320 that is generally perpendicular to the horizontal plane 318. Additionally, the general incline of each of the forefoot portion 302 and the heel portion 304 prevent undercut in the mold that could lock the sole structure in the mold 300.

In general, the above-described protruding members, such as protruding members 136, 144, 200, 220, 266, 274 provide a structure for a cleat assembly where each cleat member is generally angled toward a midfoot portion of an article of footwear. Likewise, the mold 300 described above provides a mold for a sole structure having cleat members that are generally angled toward a midfoot portion of an article of footwear. Such cleat members can provide an aggressive style that can increase traction capabilities. Additionally, the geometry of such cleat members facilitate an injection molding process that overcomes undercut complications without introducing unnecessary parting lines.

Any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with different embodiments. Further, the present disclosure is not limited to articles of footwear of the type specifically shown. Still further, aspects of the articles of footwear of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

As noted previously, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

INDUSTRIAL APPLICABILITY

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the appended claims are reserved. 

We claim:
 1. An article of footwear, comprising: an upper; a sole structure connected to the upper; and a cleat assembly connected to the sole structure, the cleat assembly including: a first protruding member extending from a first base, the first protruding member defining a first midfoot-facing portion and a forefoot-facing portion; a second protruding member extending from a second base, the second protruding member defining a second midfoot-facing portion and a heel-facing portion; a first acute angle defined by the first base and the first midfoot-facing portion; a first obtuse angle defined by the first base and the forefoot-facing portion; a second acute angle defined by the second base and the second midfoot-facing portion; and a second obtuse angle defined by the second base and the heel-facing portion.
 2. The article of footwear of claim 1, wherein each of the first obtuse angle and the second obtuse angle is between 95 degrees and 145 degrees.
 3. The article of footwear of claim 1, wherein each of the first acute angle and the second acute angle is between 35 degrees and 85 degrees.
 4. The article of footwear of claim 1, wherein the first base is formed from a forefoot portion of the cleat assembly that is disposed at least partially in a forefoot region of the article of footwear and the second base is formed from a heel portion of the cleat assembly that is disposed at least partially in a heel region of the article of footwear.
 5. The article of footwear of claim 1, wherein the first protruding member is part of a plurality of protruding members and the second protruding member is part of a second plurality of protruding members.
 6. The article of footwear of claim 5, wherein at least one protruding member of the first or second plurality of protruding members includes a ground engaging surface that is parallel to a portion of the respective first or second base.
 7. The article of footwear of claim 5, wherein each protruding member of the first plurality of protruding members and the second plurality of protruding members are angled toward a midfoot portion of the article of footwear.
 8. The article of footwear of claim 5, wherein the first plurality of protruding members is integrally formed and the second plurality of protruding members is integrally formed.
 9. The article of footwear of claim 1, wherein each of the first protruding member and the second protruding member include a first removable stud tip and a second removable stud tip, respectively.
 10. The article of footwear of claim 1, wherein each of the first protruding member and the second protruding member include an injection molded polymeric material that is scratch-resistant.
 11. The article of footwear of claim 1, wherein the first protruding member includes a tapered geometry so that a wider portion of the first protruding member is disposed proximate to the first base and the second protruding member includes a tapered geometry so that a wider portion of the second protruding member is disposed proximate to the second base.
 12. An article of footwear, comprising: an upper; a sole structure connected to the upper and defining a forefoot region, a midfoot region, and a heel region; and a cleat assembly secured to the sole structure, the cleat assembly including: a forefoot portion secured to the sole structure at the forefoot region and including a first plurality of protruding members extending from a first base, the first plurality of protruding members angled toward the midfoot region; and a heel portion secured to the sole structure at the heel region and including a second plurality of protruding members extending from a second base, the second plurality of protruding members angled toward the midfoot region.
 13. The article of footwear of claim 12, wherein each protruding member of the first plurality of protruding members defines a respective ground engaging surface, and wherein a surface area of the respective ground engaging surfaces of the first plurality of protruding members closer to the midfoot region are greater than the ground engaging surfaces of the first plurality of protruding members that are closer to the forefoot region.
 14. The article of footwear of claim 12, wherein each of the first plurality of protruding members and the second plurality of protruding members include a respective removable stud tip.
 15. The article of footwear of claim 12, wherein at least a portion of the first base is integrally formed with at least one protruding member of the first plurality of protruding members via injection molding, and wherein at least a portion of the second base is integrally formed with at least one protruding member of the second plurality of protruding members via injection molding.
 16. The article of footwear of claim 12, wherein at least one protruding member of the first plurality of protruding members defines a midfoot-facing side wall and a forefoot-facing side wall, the midfoot-facing side wall forming an acute angle with the first base and the forefoot-facing side wall forming an obtuse angle with the first base.
 17. The article of footwear of claim 16, wherein the midfoot-facing side wall is integrally formed with the forefoot-facing side wall.
 18. The article of footwear of claim 12, wherein at least one protruding member of the second plurality of protruding members defines a midfoot-facing side wall and a heel-facing side wall, the midfoot-facing side wall forming an acute angle with the second base and the heel-facing side wall forming an obtuse angle with the second base.
 19. A method of forming a cleat assembly, the method comprising: injecting a first material into a mold cavity to form a cleat assembly, the mold cavity including a plurality of stud recesses that each define a respective stud recess base disposed along an incline that defines an acute exterior angle relative to a horizontal plane; and removing the cleat assembly from the mold cavity at an angle that is substantially perpendicular to the horizontal plane.
 20. The method of claim 19, further comprising: securing the cleat assembly to a sole structure of an article of footwear. 